Method and system for forming a self-sealing volume

ABSTRACT

A method and system for forming a self-sealing volume includes an elastomeric composite structure. The structure includes layers of a cast polyurethane derived from a neat polyurethane monomer reaction mixture that does not substantially react at room temperature. The polyurethane monomer reaction layer includes a reaction product of an organic polyisocyanate and a reactive hydrogen-containing material reacted with a mixture of a monomeric polyol and polymeric polyols. The structure may further include one or more layers of a fabric that have been precoated with an aliphatic polyurethane, and one or more sealing layers. A fuel impermeable inner liner may be positioned in an inner region. The sealing layers may comprise at least one of partially vulcanized natural rubber (NR), polyisoprene (IR), styrene butadiene (SBR), or a blend of SBR with NR or IR. A dimensionally correct, self-sealing volume may be created by inflating the volume during its cure.

PRIORITY AND RELATED APPLICATIONS STATEMENT

This Application claims priority under 35 U.S.C. §119(e) to provisional patent application Ser. No. 61/651,633, filed on May 25, 2012, entitled, “METHOD AND SYSTEM FOR FORMING A SELF-SEALING VOLUME.” The entire contents of this provisional patent application are hereby incorporated by reference.

This Application is also related to U.S. Non-Provisional patent application Ser. No. 13/796,775, filed on Mar. 12, 2013, entitled, “METHOD AND SYSTEM FOR FORMING A SELF-SEALING VOLUME.”

DESCRIPTION OF THE RELATED ART

The present invention is related generally to the field of containers for materials, and more specifically related to the field of self-sealing fuel tanks. These tanks are frequently preferred in applications where fuel fire and explosion risks are high, as in military, armored and racing vehicles.

Self-sealing fuel tanks currently exist in the conventional art. One problem with these conventional self-sealing fuel tanks is that they are manufactured using labor intensive hand lay up processes that require long cure times. Large numbers of self-sealing fuel tanks thus cannot be manufactured over a reasonable time period.

In addition, these conventional manufacturing techniques do not allow for precise control of the outer dimensions of self-sealing fuel tank, a problem where tight fits are required and maximum fuel capacity is desired. A closed molding process with conformable materials would allow for precise control of the outer dimensions of self-sealing fuel tanks.

Alternative materials of manufacture can be used that do not require the labor intensity and long cure times but these materials typically prevent the use of a closed molding process since such materials require certain fluids to be evaporated during the molding process. For example, using a solvated polyurethane in a spray application usually requires fluids to be evaporated and would negate the use of a closed mold. Meanwhile, these materials do offer higher production rates, but as understood by one of ordinary skill in the art, it is not possible to carefully control the outer dimensions of the self-sealing fuel tank. In addition, as understood by one of ordinary skill in the art and mentioned above, it usually is not possible to control the evaporation of certain fluids of these materials during a closed molding process.

Accordingly, there is a need in the art for different materials for use in forming self-sealing volumes that can be used in a closed molding process where it is possible to eliminate the evaporation of fluids and precisely control the fuel tank outer dimensions.

BRIEF SUMMARY OF THE INVENTION

A method and system for forming a self-sealing volume are described. The system includes an elastomeric composite structure comprising at least one layer of a cast polyurethane derived from a neat (no solvent) polyurethane reaction mixture that does not substantially react at room temperature. The polyurethane reaction layer comprises a reaction product of an organic polyisocyanate and a reactive hydrogen-containing material that consists of a mixture of a monomeric polyol and polymeric polyols. The structure further may include at least one layer of a fabric, and at least one sealing layer. A fuel impermeable inner liner may be positioned in an inner region relative to the other layers. The fabric may comprise fibers made from nylon materials.

The at least one sealing layer may comprise at least one of an unvulcanized or partially vulcanized natural rubber (NR), a polyisoprene (IR), a styrene butadiene (SBR), or a blend of these materials. In other exemplary embodiments, the sealing layer may comprise polyurethane. The reactive hydrogen-containing material may comprise at least one or more of a polyester polyol, a polyether polyol, or a hydrocarbon-polyol. In other exemplary embodiments, the sealant layer may be unvulcanized (no curative) rubber are partially vulcanized (<1% sulfur). In other exemplary embodiments, the sealing layer may comprise fully vulcanized (>1% sulfur) rubber. Other alternative materials for the sealing layer may include, but are not limited to, aliphatic polyurethanes.

According to another aspect of the inventive system and method, a preform used to create the self-sealing volume includes positioning a fixture or a plurality of fixtures into a mold and placing preform material into a mold and which adheres to the fixture. The preform may then be coated with a gas-impermeable elastomeric release material that forms a gas impermeable seal around a geometry of the preform. The preform material may comprise at least one of polyurethane, polyester, plaster and polystyrene. Meanwhile, the gas-impermeable elastomeric release material may comprise at least one of: a silicone, an elastomeric silicone, a polyvinyl alcohol (PVA), and a polyolefin mold release agent. The inventive system may further include creating one or more apertures within the preform in order to assist with inflation of the release material during curing of the material forming the self-sealing volume. The end product of the self-sealing volume does not have any apertures except for the access port that receives a fixture and a nut ring. Prior to applying the material forming the self-sealing volume or any silicone to the preform, the size of the preform may be slightly adjusted so that the outer dimensions of the preform generally correspond to the inner dimensions of the self sealing volume.

Another inventive aspect of the method and system is that the preform is inflated during curing of the polyurethane reaction mixture layer. With this inflation of the preform, the polyurethane reaction layer conforms to the exact dimensions of the mold which holds the preform and the polyurethane reaction mixture sandwiched there between. This process yields a dimensionally correct/precisely built self-sealing volume.

BRIEF DESCRIPTION OF THE DRAWINGS

In the Figures, like reference numerals refer to like parts throughout the various views unless otherwise indicated. For reference numerals with letter character designations such as “102A” or “102B”, the letter character designations may differentiate two like parts or elements present in the same figure. Letter character designations for reference numerals may be omitted when it is intended that a reference numeral to encompass all parts having the same reference numeral in all Figures.

FIG. 1A is a cross-sectional view of a self-sealing volume in the form of a fuel tank according to one exemplary embodiment.

FIG. 1B is a cross-sectional view of a portion of a wall of a self-sealing volume according to one exemplary embodiment.

FIG. 2A is a cross-sectional view of an entire wall for a self-sealing volume according to the exemplary embodiment of FIG. 1.

FIG. 2B is a cross-sectional view of the wall of FIG. 2A in which a projectile has begun to penetrate the wall entering from outside of the self-sealing volume towards the inside of the volume containing a fluid, such as fuel.

FIG. 2C is a cross-sectional view of the wall of FIG. 2B in which the projectile has continued to penetrate the wall from the outside of the self-sealing volume towards the inside of the volume containing a fluid, such as fuel.

FIG. 2D is a cross-sectional view of the wall of FIG. 2C in which the projectile has continued to penetrate the wall from outside of the self-sealing volume towards the inside of the volume containing a fluid, such as fuel.

FIG. 2E is a cross-sectional view of the wall of FIG. 2D in which the projectile has completely penetrated the wall and has entered into the volume containing the fluid, such as fuel, and allowing the fluid to react with the sealing layer.

FIG. 2F is a cross-sectional view of the wall of FIG. 2E in which the fluid continues to react with the sealing layer causing the sealing layer to further expand into the close the volume containing the fluid.

FIG. 3A is a diagram illustrating fibers receiving a polyurethane coating.

FIG. 3B is a diagram illustrating a fabric receiving a polyurethane coating.

FIG. 4A is a cross-sectional view of a preform, a release layer, and a liner.

FIG. 4B is a cross-sectional view of an intermediate product that comprises the wall layers of FIG. 1 in addition to the preform, the release layer, and liner of FIG. 4A.

FIG. 4C is a diagram illustrating how the intermediate product of FIG. 4B is positioned within a mold according to one exemplary embodiment.

FIG. 4D is a diagram illustrating a cured intermediate product after the intermediate product is removed from the mold of FIG. 4C.

FIG. 4E is a diagram illustrating the formation of the completed product of FIGS. 2A-2F by removing of the preform and release layer.

FIG. 5A is a flowchart illustrating a method for forming a self-sealing volume according to an exemplary embodiment.

FIG. 5B is a continuation flowchart of FIG. 5A illustrating the method for forming a self-sealing volume according to an exemplary embodiment.

FIG. 5C is a continuation flowchart of FIG. 5B illustrating the method for forming a self-sealing volume according to an exemplary embodiment.

FIG. 6 a flowchart illustrating a routine or submethod for creating a polyurethane reaction mixture according to an exemplary embodiment.

FIG. 7A1 is a cross-sectional view of a device for forming flexible molds according to an exemplary embodiment.

FIG. 7A2 is a cross-sectional view of the flexible molds formed from the device of FIG. 7A1 according to an exemplary embodiment.

FIG. 7A3 is a cross-sectional view of preform material positioned within the flexible molds of FIG. 7A2 according to an exemplary embodiment.

FIG. 7A4 is a cross-sectional view of the two halves of a gas-permeable, solid preform generated from the flexible molds of FIG. 7A3 according to an exemplary embodiment.

FIG. 7A5 is a cross-sectional view of the two halves of the gas-permeable, solid preform put together according to an exemplary embodiment.

FIG. 7A6 is a cross-sectional view of the two halves of the gas-permeable, solid preform after apertures or holes have been created within the preform according to an exemplary embodiment.

FIG. 7B1 is a cross-sectional view of a solid mold for forming an gas-impermeable, hollow preform according to an exemplary embodiment.

FIG. 7B2 is a cross-sectional view of the solid mold of FIG. 7B1 with a fixture attached to a side of the solid mold having an aperture according to an exemplary embodiment.

FIG. 7B3 is a cross-sectional view of the solid mold in which a liquid state of the preform material is poured into the solid mold via the fixture according to an exemplary embodiment.

FIG. 7B4 is a cross-sectional view of the solid mold containing the preform liquid material while the solid mold is being rotated according to an exemplary embodiment.

FIG. 7B5 is a cross-sectional view of the solid mold being opened after curing of the preform liquid material into an gas-impermeable, hollow preform according to an exemplary embodiment.

FIG. 7B6 is a cross-sectional view of the gas-impermeable, hollow preform after apertures or holes have been created within the preform according to an exemplary embodiment.

FIG. 7C illustrates a cross-sectional view of a device for forming flexible molds according to an exemplary embodiment.

FIG. 8 is a flowchart illustrating a routine or submethod for generating the solid preform of FIG. 7A according to an exemplary embodiment.

FIG. 9 is a flowchart illustrating a routine or submethod for generating the hollow preform of FIG. 7B according to an exemplary embodiment.

DETAILED DESCRIPTION OF THE INVENTION

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any aspect described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects.

FIG. 1A is a cross-sectional view of a self-sealing volume or wall system 200 in the form of a fuel tank according to an exemplary embodiment. The wall system 200 comprises a wall 100 and a liner 202 which will be described in more detail below. The wall system 200 may contain a fluid 204, such as, but not limited to, a hydrocarbon fuel. The wall system 200 may further comprise a nut ring 509 containing an access port 405 which will be described below in connection with FIGS. 4C-4E. The wall system 200 may comprise a composite of elastomeric material and fabric as described in further detail below. The composite of elastomeric material and fabric may include a self-healing layer for sealing after ballistic penetration.

Referring now to FIG. 1B, this figure is a cross-sectional view of a portion of a wall 100 for forming the self-sealing volume or wall system 200 (of FIG. 1A) according to one exemplary embodiment. The wall 100 may comprise an elastomeric composite that includes a combination of layers such as, for example, a polyurethane reaction mixture layer 102, a fabric or fiber layer 104, and a sealant layer 106.

In the exemplary embodiment illustrated in FIG. 1B, the wall 100 may comprise a first polyurethane reaction mixture layer 102A, a first fabric or fiber layer 104A, a second polyurethane reaction mixture layer 102B, a sealant layer 106, a third polyurethane reaction mixture layer 102C, a second fabric were fiber layer 104B, and a fourth polyurethane reaction mixture layer 102D.

Each polyurethane reaction mixture layer 102 may be made by reacting an organic diisocyanate or diisocyanate prepolymer with a reactive hydrogen-containing material having a molecular weight of about 700.0 to about 4000.0 and then curing the reaction product as described below in connection with the flow chart of the method 500 illustrated in FIG. 5. The polyurethane reaction mixture layers 102 do not substantially react at room temperature, which is typically about 25.0° C. as understood by one of ordinary skill in the art.

Representative of the reactive hydrogen-containing materials are the broad classes of polyester polyols, polyether polyols, hydrocarbon-polyols. The polyester polyols that are preferred include the esters of adipic acid with the lower glycols such as ethylene glycol, propylene glycol, and butylene glycol, and higher glycols such as polyethylene glycol and polypropylene glycol and mixtures of these. The polyether polyols that are preferred include ethylene ether glycol, polyethylene ether, propylene ether glycol, polypropylene ether polyol, and polytetramethylene ether polyol and mixtures of these.

In conjunction with the polyol a short chain glycol, organic diamine or alkylanolamine may be used to increase the molecular weight of the polyurethane reaction mixture layer 102. Representative members of these classes of glycols, organic diamines or alkylanolamines useful in the present invention include, but are not limited to, ethylene glycols, propylene glycols, butane diols, methylene bis-chloroaniline, methylene dianiline, bis-amino phenyl sulfone and amino methyl propanol. If organic amines are used, then urea linkages will be created rather than urethane linkages, resulting in a mixed polyurethane urea.

Normally, any of the well-known organic polyisocyanates useful for making castings may be utilized for the polyurethane reaction mixture layer 102, with toluene diisocyanate and methylene diphenyldiisocyanate exemplifying the ones most frequently used. The polyisocyanates are normally reacted at about 0.8 to about 1.5 mols per each mol of reactive hydrogen-containing material.

A cross-linking monomer, such as a crosslinking polyol, may be used in the polyurethane reaction mixture layer 102 in order to improve the compression set. As understood by one of ordinary skill in the art, compression set is the tendency of elastomers to undergo permanent deformation. It is the tendency of some elastomers to not recover in a completely elastic manner. An addition of a crosslinking polyol such as described above may remedy this characteristic. This compression set property may be measured by ASTM D395.

Further, a rubber adhesion activator monomer, such as allyl-alcohol, also may be used in the polyurethane reaction mixture layer 102 in order to improve its adhesion properties to rubber. This adhesion activator monomer may improve the adhesion of the polyurethane reaction mixture layer 102 to the sealant layer 106 by providing an active group (alcohol) for bonding with the polyurethane reactive ingredients of the polyurethane reaction mixture layer 102 and an active group (olefin) that will react with the rubber of the sealant layer 106 during vulcanization.

One of ordinary skill in the art will appreciate that if the preferred polyurethanes can be applied as a somewhat fluid polyurethane reaction mixture layer 102, then this polyurethane reaction mixture layer 102 may more readily coat the fiber or fabric layer 104 before the polyurethane has had a chance to react to form an intractable polymer. This is done by selecting a polyurethane reaction mixture that has a relatively long gel time, such as on the order of about 30 minutes to about 120 minutes. The preferred gel time may comprise a period of between about 15.0 to about 90.0 minutes. A gel time comprises an interval of time required for the polyurethane reaction mixture layer 102 to become a solid or semisolid gel prior to fully reacting to form a polyurethane.

The polyurethane reaction mixture layer 102 may be applied by brushing, troweling, swabbing, dipping or spraying, or other ways as understood by one of ordinary skill in the art. After the polyurethane reaction mixture layer 102 has been sufficiently spread and incorporated into the fabric or fiber layer 104, then the polyurethane reaction mixture layer 102 is ready to be cured.

The polyurethane reaction mixture layer 102 is selected such that heat is required for reaction and cure. Heat can be supplied from a conventional oven, an autoclave, a microwave oven or from a press, or alternative ways as understood by one of ordinary skill in the art. Once the liquid polyurethane reaction mixture layer 102 is applied onto the respective composite layers of the wall portion 100, the entire uncured structure may be placed into a three dimensional, dimensionally correct mold 400 (as will be described below in connection with FIG. 4). Curing is effected by heating the mold 400 to a sufficient temperature and for a sufficient time to cause the polyurethane reaction mixture layer 102 to react and form a solid polyurethane layer 102. A sufficient temperature for curing is generally between about 80.0° C. to about 175.0° C., and preferably between about 100.0° C. to about 150.0° C., and more preferably at about 120.0° C. However, other temperatures may be used as understood by one of ordinary skill in the art and are within the scope of this disclosure. The time for curing is generally between about 20.0 minutes to about 360.0 minutes (min), and preferably between about 60.0 min to about 120.0 min, and more preferably for about 90.0 min. However, other times may be used as understood by one of ordinary skill in the art and are within the scope of this disclosure. As noted previously, the amount of pressure provided by the gaseous pressure source 403 is generally between about 2.0 psi to about 80.0 psi, and preferably between about 10.0 psi to about 40.0 psi, and more preferably at about 20.0 psi. However, other pressures may be used as understood by one of ordinary skill in the art and are within the scope of this disclosure.

The fabric or fiber layer 104 may comprise coated polyamide fibers or coated fabrics. The coating on the fibers or fabrics in layer 104 may comprise solvated or aliphatic polyurethane that is applied during the fiber or fabric manufacturing process. As understood by one of ordinary skill in the art, aliphatic is a general class of polyurethanes (excluding aromatic) which is typically easier to solvate than aromatic polyurethanes. The coating may also comprise a resorcinol formaldehyde (RFL) or an isocyanate. Further details of this coating for the fibers or fabric layer 104 are described below in connection with FIGS. 3A-3B

The fabric or fibers in layer 104 may comprise polyamide or polyester fibers. As understood by one of ordinary skill in the art, polyamide is a class that includes NYLON and anisotropic aromatic polyamide (such as KEVLAR™). As understood by one of ordinary skill in the art, polyester is a class that includes polyethylene terephthalate and anisotropic aromatic polyester. The fabric may comprise at least one of NYLON 6, NYLON 66, polyester, an anisotropic aromatic polyamide, or an anisotropic aromatic polyester from about 5.0 ounces per square yard (“oz/SY”) to about 30.0 oz/SY. It is possible to use other fibers and fabrics with the polyurethane reaction mixture layer 102, but polyamide and polyester fibers and fabrics are preferred due to their physical performance characteristics in ballistic and blast situations.

The sealant layer 106 typically is sandwiched between two polyurethane reaction mixture layers 102 and two or more fabric or fiber layers 104 for reinforcement. Typical materials suitable for use as the sealant layer 106 may comprise unvulcanized, partially vulcanized and/or vulcanized natural rubber (NR). Other materials that may be used include polyisoprene (IR), styrene butadiene (SBR) and blends of SBR with NR or IR. In other exemplary embodiments, the sealant layer 106 may be unvulcanized. In other exemplary embodiments, the sealant layer 106 may comprise fully vulcanized (>1.0% sulfur) rubber. Other alternative materials for the sealant layer 106 may include, but are not limited to, aliphatic polyurethanes

While the thicknesses of each of the layers illustrated in FIG. 1 have been shown to be equivalent, one of ordinary skill in the art will recognize that the actual thicknesses of each layer may vary and may be adjusted depending upon the level of protection desired for a particular volume. Wall gauge design dimensions are usually driven by weight restrictions, ballistic needs and overall flexibility requirements. For example, the finished product for the self-sealing wall portion 100 typically has the following dimensions according to one illustrative embodiment: a first polyurethane reaction mixture layer 102A having a thickness of approximately 0.1 to approximately 1.0 mm; a first fabric or fiber layer 104A having a thickness of approximately 0.5 to approximately 2.0 mm; a second polyurethane reaction mixture layer 102B having a thickness of approximately 0.1 to approximately 1.0 mm; a sealant layer 106 having a thickness of approximately 0.5 to approximately 13.0 mm; a third polyurethane reaction mixture layer 102C having a thickness of approximately 0.1 to approximately 1.0 mm; a second fabric or fiber layer 104B having a thickness of approximately 0.5 to approximately 2.0 mm; and a fourth polyurethane reaction mixture layer 102D having a thickness of approximately 0.1 to approximately 1.0 mm.

Further, one of ordinary skill in the art will recognize that the number and size of the layers may be varied without departing from the scope of the present disclosure. That is, fewer or a greater number of layers with different thicknesses may be used for a particular embodiment without departing from the scope of the technology described herein.

Referring now to FIG. 2A, this figure is a cross-sectional view of an entire wall or wall system 200 for a self-sealing volume according to one exemplary embodiment. The wall system 200 comprises all of the layers of the wall 100 described above in connection with FIG. 1B, in addition to a liner layer 202 and the fluid 204.

The liner layer 202 may comprise any elastomeric material that will have a greater resistance to hydrocarbon fuel 204 than a polyurethane elastomer. Exemplary materials include, but are not limited to, nitrile rubber, polyurethane, polysulfide and polyvinylidene fluoride, polyurea, polyvinylalcohol (PVA), Hydrogenated Nitrile Butadiene Rubber (HNBR), Epichlorohydrin rubber (ECO), or any fuel resistant elastomer. An optional barrier layer, described below, may also be used and positioned on the outside of the liner layer 202.

The fluid 204 may comprise a fuel, and particularly a hydrocarbon fuel 204, such as gasoline, diesel-based fuels, biofuels, ethanol fuels used in military crafts such as airplanes, boats, helicopters, tanks, cars, jeeps, all-terrain-vehicles (ATVs), and other similar vehicles. The wall 100 provides a self-sealing barrier and protection for the liner layer 202 in order to contain the fluid 204 within the entire wall system 200.

FIG. 2B is a cross-sectional view of the wall system 200 of FIG. 2A in which a projectile 206 has begun to penetrate the wall system 200 entering from outside of the self-sealing volume towards the inside of the volume containing a fluid 204, such as fuel. The projectile 206 may comprise any type of object that is launched from a gun or ballistic system, such as a bullet or fragment, and/or fragments from high velocity vehicle accidents. In the exemplary embodiment illustrated in FIG. 2B, the projectile 206 has already penetrated the first polyurethane reaction mixture layer 102A and is starting to enter the first fabric or fiber layer 104A.

FIG. 2C is a cross-sectional view of the wall system 200 of FIG. 2B in which the projectile 206 has continued to penetrate the wall system 200 from the outside of the self-sealing volume towards the inside of the volume containing a fluid 204, such as fuel. In this exemplary embodiment, the projectile 206 has penetrated through the first polyurethane reaction mixture layer 102A, the first fabric or fiber layer 104A, the second polyurethane reaction mixture layer 102B, the sealant layer 106, the third polyurethane reaction mixture layer 102C, the second fabric or fiber layer 104B, and has started to enter the fourth polyurethane reaction mixture layer 102D.

FIG. 2D is a cross-sectional view of the wall system 200 of FIG. 2C in which the projectile 206 has continued to penetrate the wall system 200 from outside of the self-sealing volume towards the inside of the volume containing a fluid 204, such as fuel. In this exemplary embodiment, the projectile 206 has penetrated through all the layers of the wall system 200 including the liner layer 202 and has entered the volume containing the fluid 204 itself. Specifically, the projectile 206 has penetrated through all four layers of the polyurethane reaction mixture layers 102, the two fiber or fabric layers 104, the single sealant layer 106, and the liner layer 202.

FIG. 2E is a cross-sectional view of the wall system 200 of FIG. 2D in which the projectile has completely penetrated the wall system 200 and has entered into the volume containing the fluid 204, such as fuel, thus allowing the fluid 204 to react with the sealant layer 106. In this exemplary embodiment, the fluid 204 which may comprise a fuel such as a hydrocarbon fuel may interact with the sealant layer 106 which may comprise unvulcanized or partially vulcanized natural rubber (NR). Other materials that may be used for the sealant layer 106, as described above, may include but are not limited to polyisoprene (IR), styrene butadiene (SBR) or blends of SBR with NR or IR.

In this exemplary embodiment, the sealant layer 106 includes a first portion 106A which has expanded into the cavity 210A formed by the projectile 206. The sealant layer 106 is selected from materials that are tacky in nature and which may have autoadhesion characteristics. Such materials may also swell around openings formed by projectiles that penetrate the materials. In other cases, it is believed that swelling of the sealant layer could occur due to a reaction between the sealant and a hydrocarbon liquids or any other type of liquid which may be stored in the self-sealing volume.

The sealant materials are generally themselves hydrocarbon elastomers such as unvulcanized or partially vulcanized, and/or fully vulcanized natural rubber (NR). Other materials that may be used for the sealant layer 106, as described above, may include but are not limited to polyisoprene (IR), styrene butadiene (SBR) or blends of SBR with NR or IR. Generally the materials selected will serve to swell into a cavity as large as that made by common projectiles 206, such as a 50 mm or 30 mm projectile, and smaller. The projectile 206 may comprise in-tact bullets, missiles, grenades, etc., and/or fragments thereof, and/or fragments from vehicle accidents/collisions.

This first portion 106A of the sealant layer 106 prevents the fluid 204 from escaping or leaking through the wall system 200 of the cavity 210A. Swelling of the sealant layer 106 initiates from the fuel side and proceeds in an outward direction. Fiber from the fabric layers 104A, 104B may also expand and fill the cavity 210 and may provide an additional, yet moderate level of sealing of the liquid 204 compared to the sealant layer 106. Meanwhile, the two polyurethane reaction mixture layers 102C and 102D remain broken by the projectile 206.

As understood by one of ordinary skill in the art, various different sealing modalities may occur with the wall system 200. Because of strength, cut resistance and elongation of wall materials, the wall system 200 may stretch (bow) inward by a significant amount before the projectile 206 penetrates into the volume containing the fluid 204. When the wall system 200 recovers to essentially a flat surface, distances between materials forming the wall system 200 may shorten, and the stretched fibers and elastomeric molecular strands within the wall system 200 may provide a puckering kind of seal around the cavity/wound/opening. This seal may include the sealant layer 106 which may facilitate autoadhesion.

FIG. 2F is a cross-sectional view of the wall system 200 of FIG. 2E in which, in some instances, it is possible the fluid 204 may react with the sealant layer 106 causing the sealant layer 106 to further expand and to close the volume containing the fluid 204. In other instances or in addition to such a reaction between the fluid 204 and sealant layer 106, the sealant layer 106 as well as others may be stretched from the projectile 206 and this sealant layer 106 may provide a puckering kind of seal around the cavity/wound/opening due to inelastic expansion. Layer 106 is usually a hydrocarbon elastomer such as unvulcanized or partially vulcanized, and/or fully vulcanized natural rubber (NR). Other materials that may be used for the sealant layer 106, as described above, may include but are not limited to polyisoprene (IR), styrene butadiene (SBR) or blends of SBR with NR or IR.

In this exemplary embodiment, the first portion 106B has further expanded into the cavity 210B that was created by the projectile 206 when it passed through the wall system 200. As noted previously, the first portion 106B that has expanded into the cavity 210B because of its reaction with the fluid 204, which may comprise a hydrocarbon fuel, may prevent the fluid 204 from leaking through the cavity 210B formed by the projectile 206.

Referring now to FIG. 3A, this figure is a diagram illustrating fibers 105 receiving a polyurethane coating 301A. The coating 301A on the fibers 105 used to form a fiber layer 104C1 of FIGS. 1-2 may comprise solvated aliphatic polyurethane that is applied during the fiber or fabric manufacturing process. As understood by one of ordinary skill in the art, aliphatic is a general class of polyurethanes (excluding aromatic), which typically is easier to solvate than aromatic polyurethanes. Other materials in addition to polyurethanes can be used, such as a resorcinol formaldehyde latex (RFL) and an isocyanate.

FIG. 3B is a diagram illustrating a fabric comprising fibers 105 receiving a polyurethane coating 301B. The coating 301B on the fibers 105 used to form fabric layer 104C of FIGS. 1-2 may comprise solvated aliphatic polyurethane that is applied during the fiber or fabric manufacturing process. FIG. 3B further illustrates a nozzle 305 that may be used to apply the coating 301B of polyurethane to the fibers 105 of the fabric layer 104C2. Other ways or methods for applying the coating 301 may be used other than those illustrated in FIGS. 3A-3B, such as by applying the solvated polyurethane to the fabric layer 104C2 with a roller applicator or in a dip.

FIG. 4A is a cross-sectional view of one-half of a gas-impermeable, hollow preform or gas permeable solid preform 304, an elastomeric mold release layer 302, and a liner 202. The half-structure is noted by dashed line 402. As noted previously, the liner 202 layer may comprise any elastomeric material that will have a greater resistance to hydrocarbon fuel 204 than a polyurethane elastomer. Exemplary materials include, but are not limited to, polyurethane, nitrile rubber, polysulfide, polyurea, polyvinylalcohol (PVA), Hydrogenated Nitrile Butadiene Rubber (HNBR), Epichlorohydrin rubber (ECO), and/or polyvinylidene fluoride.

The preform 304 may comprise a molded or shaped object that has the general shape and dimensions representing the inside volume of a fuel tank. The preform 304 is gas-permeable or gas impermeable and it may comprise a solid hard material, in that the preform preferably may support the weight of the wall portion 100 illustrated in FIG. 1 during manufacturing. Suitable materials for the preform 304 may include, but are not limited to, polyurethane, polyurea, polyester or polystyrene foams. The preform 304 may be formed to have a shape suitable for a mold or it may be cut and sculpted to a desired shape. According to some exemplary embodiments, the preform 304 may comprise a gas-permeable solid structure such as illustrated in FIG. 7A (described below) or the preform 304 may comprise an gas-impermeable hollow structure such as illustrated in FIG. 7B (described below). The inventive system 200 and method 500 may also employ foam board performs 304 as understood by one of ordinary skill in the art as an alternative to the preform material 304A, 304B used for the gas-permeable structures of FIG. 7A.

In the exemplary embodiment illustrated in FIG. 4A, the cross-sectional shape of the gas-permeable, hollow preform 304 may comprise a rectangular shape or a more complex shape. As noted above, other cross-sectional shapes are possible and are within the scope of the disclosure described herein. Other cross-sectional shapes include, but are not limited to, oval, cylindrical, triangular, hexagonal (See FIGS. 7A-7B), octagonal, and other like shapes or more complex shapes that may be conducive for use as fuel tanks on military crafts and/or other vehicles, such as, but not limited to, police cars, race cards, armored vehicles, etc.

Positioned between the liner 202 and the preform 304 is an elastomeric mold release layer 302. The elastomeric mold release layer 302 may have at least two purposes. First, it may serve as an elastomeric bag that will allow gaseous pressurization from inside the perform 304. The gaseous pressure serves to expand the elastomeric mold release layer 302 and subsequently push the uncured wall 100 structure against the surfaces of mold 400A and 400B. In most cases, it is important that the elastomeric mold release layer 302 be leak tight during pressurization. Second, the elastomeric mold release layer 302 may serve as a mold release between the preform 304 and the liner 202. The elastomeric mold release layer 302 may comprise any conventional mold release material. Suitable mold release materials include, but are not limited to, silicone, elastomeric silicone, polyvinyl alcohol (PVA), polyolefin, or oil or grease mold release agents.

One of ordinary skill in the art will appreciate that the thicknesses illustrated in the cross-sectional view of FIG. 4A may have been exaggerated for viewing purposes. The thicknesses of the liner 202, the elastomeric mold release layer 302, and the preform 304 may be varied without departing from the scope of the disclosure described herein. According to one exemplary embodiment, the liner layer 202 may have a thickness of approximately 0.1 to approximately 1.0 mm, while the elastomeric mold release layer 302 may have a thickness of approximately 0.5 to approximately 2.0 mm, and the preform 304 may have a thickness of approximately 1.0 to approximately 10.0 mm. The preform 304 may be a monolithic solid structure, a hollow structure, or a layered structure, for example.

FIG. 4B is a cross-sectional view of an intermediate product 300 that comprises the wall portion 100 of FIG. 1 in addition to the preform 304, the release layer 302, and liner 202 as illustrated in FIG. 4A. The intermediate product 300 is characterized as such (“intermediate”) because the preform 304 and elastomeric mold release layer 302 are not utilized in the end product for containing a fluid 204, such as a fuel. The illustration of the intermediate product 300 of FIG. 4A is helpful in understanding how a completed fuel tank or final product forming the wall system 200 as illustrated in FIGS. 2 and 4E-4E is manufactured.

FIG. 4C is a diagram illustrating how the intermediate product 300A of FIG. 4B (which comprises the preform 304 and the elastomeric mold release layer 302 but no liquid 204) is positioned within a mold 400 and coupled to a gaseous pressure source 403 according to one exemplary embodiment. According to this exemplary embodiment, the intermediate product 300A has a hexagonal shape compared to the rectangular cross-sectional shape illustrated in FIG. 4B.

In the exemplary embodiment illustrated in FIG. 4C, the mold 400 may comprise two halves 400A, 400B which are joined together. The two halves 400A, 400 may be coupled together by any type of mechanical fastener, such as, but not limited to a hinge. Other types of molds 400, such as a two piece compression mold 400, as well as other molding techniques may be employed such as compression molding and vacuum bag molding. The actual number of mold sections can be more than two and is dictated by each individual volume geometry requirement. The mold section design also aids in the removal of the final product once the curing is complete. The mold 400 controls the dimension of the final product, which is the wall system/self-sealable volume 200 as illustrated in FIG. 1A. Exemplary dimensions for the mold include, but are not limited to, about 499.00 mm by about 555.00 mm by about 96.50 mm (or about 19.65 inches by about 21.85 inches by about 3.80 inches). It is noted that the 19.65 inches measurement corresponds to the 19.79 inches measurement for the self sealing volume listed in Table 1 described below. It is further noted that the preform 304 does not control the final dimensions of the wall system/self-sealable volume 200.

After curing of the intermediate product 300A within the mold 400 and later removal of the preform 304 and elastomeric mold release layer 302, the cured structure forms the final wall system 200 of a self-sealing volume as illustrated in FIG. 4E and FIG. 2. The mold 400 may comprise a heat source 410 for generating heat to apply to the intermediate product 300A contained within the mold 400. A heat source 410 may comprise any type of heat appropriate for molding or curing polyurethane structures as understood by one of ordinary skill in the art. Exemplary heat sources 410 include, but are not limited to, conventional ovens, like convection ovens, microwave ovens, attached electrical strip heaters, autoclaves or attached tubing containing heated oil.

The mold 400 may also comprise a gaseous pressure source 403, like a pump, for generating gaseous pressure to apply to the intermediate product 300A contained within the mold 400. Specifically, the gaseous pressure source 403 may be coupled to an inlet 503. The inlet 503 may be coupled to a metal fixture 507 that is contained within a nut ring 509. A nut ring 509 may comprise an access port for fuel filling, venting, and a fuel pump. Each metal fixture 507 may be fitted with one nut ring 509. Multiple metal fixtures 507 with nut rings 509 may be used for redundancy and/or for different connections to the resultant self-sealing volume 100 which is designed to contain fuel.

Each self-sealing volume 100 may have one or more nut rings 509. Each nut ring 509 may be fitted with cords or fabric flanges that extend radially into the elastomeric composite 100 to provide secure attachment of the nut ring 509 to the self-sealing volume 100. A nut ring is described and illustrated in U.S. Pat. No. 3,704,190, the entire contents of which are hereby incorporated by reference. A nut ring may have a circular shape. However, it may have other shapes too, such as, but not limited to, oval, rectangular, rectangular with rounded edges, pentagonal, octagonal, etc.

A gaseous pressure source 403 may comprise any type of gaseous pressure appropriate for forming a shaped part of polyurethane structures as understood by one of ordinary skill in the art. Exemplary gaseous pressure sources 403 include, but are not limited to, compressed air from a compressed cylinder or from a conventional air compressor, or compressed nitrogen, argon, carbon dioxide or helium from a compressed cylinder.

As noted previously, the elastomeric mold release layer 302 forms a gas tight seal around the preform 304 when the elastomeric mold release layer 302 is inflated by the gaseous pressure source 403. The elastomeric mold release layer 302 will expand the polyurethane reaction mixture layers 102 when the elastomeric mold release layer 302 is inflated with a gas from the gaseous pressure source 403. The amount of pressure provided by the gaseous pressure source 403 is generally between about 2.0 psi to about 80.0 psi, and preferably between about 10.0 psi to about 40.0 psi, and more preferably at about 20.0 psi. However, other pressures may be used as understood by one of ordinary skill in the art and are within the scope of this disclosure.

FIG. 4D is a diagram illustrating a cured intermediate product 300C after the intermediate product 300C is removed from the mold 400 of FIG. 4C, disconnected from the inlet 503 and gas pressure source 403, and after the intermediate product 300C has been cured. The intermediate product 300C may have any three dimensional shape including regular cubic square or rectangular cross-sectional shape or an irregular cubic quadrilateral shape or a complex multisided three dimensional shape. In the exemplary embodiment illustrated in FIG. 4D, the intermediate product 300C has a hexagonal shape.

The intermediate product 300C is characterized as such (“intermediate”) because it comprises the elastomeric mold release layer 302 and the preform 304 (internally), which are not illustrated in this figure but are illustrated in FIGS. 4A-4B. The view of FIG. 4D is an external one of the intermediate product 300C such that the internal layers, such as the elastomeric mold release layer 302 and preform 304, are not visible.

FIG. 4E is a diagram illustrating the formation of the completed product 200 of FIGS. 2A-2F by removing the preform 304 and the release layer 304. The preform 304 and release layer 302 may be removed from the intermediate product 300C, as disclosed below.

The preform 304 and elastomeric mold release layer 302 may be removed after the intermediate product 300C has been fully cured and cooled. These two structures 304, 302 may be removed by breaking them into small pieces or chunks, or a single extended piece, and removing them through nut ring 509 and access port 405. The preform 304 may be smaller relative to (have outer dimensions which are less than) the finished product 200 since the preform 304 is filled with a fluid, like air, such that the mold release layer 302 expands from the fluid. The fluid may include a gas that is used while the finished product 200 is curing. The preform 304 usually does not change in size/dimensions when the fluid is provided inside the preform 304 to inflate the mold release layer 302.

Usually, the elastomeric mold release layer 302 is usually removed with the preform 304 illustrated in FIG. 4E. Then, the preform 304 may be removed through the nut ring 509 of the finished product 200. The nut ring 509 usually has a round shape, but other shapes may be employed as understood by one of ordinary skill in the art. Once these structures 304, 302 are completely removed, the finished and completed product 200 is formed as illustrated in FIG. 1A.

Referring now to FIG. 5A, this figure is a flowchart illustrating a method 500 for forming a self-sealing volume 200 according to an exemplary embodiment. Routine block 502 is the first block of method 500. In routine or sub-method block 502, a preform 304 as illustrated in FIG. 4A and further illustrated in FIGS. 7A-7B may be generated. A preform 304 typically has a three dimensional shape as illustrated in FIGS. 4C, and 7A-7B. Further details of routine block 502 will be described below in connection with FIGS. 7A-7B, and FIGS. 8-9. The preform 304 may or may not have a symmetrical shape. At the end of block 502, a metal fixture 507 is mounted within the opening 405 of the preform mold.

Next, in block 505, the preform 304 may be coated with an elastomeric mold release material 302 as illustrated in FIG. 4A. As noted previously, this elastomeric mold release material may comprise silicone, elastomeric silicone, polyvinyl alcohol (PVA) or polyolefin mold release agents. Specifically, an elastomeric release material 302, such as SMOOTH-ON-EZ-SPRAY™ SILICONE® 20 silicone (which is a 20 Shore A silicone elastomer) may be sprayed or otherwise coated over the surface of the preform 304.

In block 510, the elastomeric mold release material 302 may be coated with a volume liner 202. Liner 202 may comprise may comprise any elastomeric material that will have a greater resistance to hydrocarbon fuel 204 than a polyurethane elastomer. Exemplary materials for the liner material 202 include, but are not limited to, polyurethane, polyurea, nitrile rubber, polysulfide, polyurea, polyvinylalcohol (PVA), Hydrogenated Nitrile Butadiene Rubber (HNBR), Epichlorohydrin rubber (ECO), and polyvinylidene fluoride. The inner liner 202 may comprise a polysulfide, such as PRC RAPID SEAL 655 ™ aliphatic polysulfide sold by PRC-DeSoto International, Inc. Or the liner 202 may comprise another fuel resistant elastomeric material. It can be sprayed in, coated or laid in as a sheet.

In block 510, a nut ring 509 may be mounted into the opening 405 of the preform mold containing the metal fixture 507 as understood by one of ordinary skill in the art. Each nut ring 509 is fitted with cords or fabric flanges that extend radially into the elastomeric composite 100 to provide secure attachment of the metal nut ring 509 to the self-sealing volume 100. These cords or fabric flanges are typically fitted on each nut ring 509 prior to starting method 500.

Alternatively, the volume 300A can be fabricated without the volume liner 202 which can be added in a subsequent step after the volume 300A is cured and the preform 304 and the elastomeric mold release layer 302 have been removed.

In an alternate exemplary embodiment, a path 522 is illustrated with a dashed line to convey that it's optional. It may be followed if the inner liner layer 202 is applied by spraying. Next, in optional block 515 (illustrated with dashed lines), the fabric or fiber layer 104 may be formed by coating the layer 104 with a solvated polyurethane. Alternatively, fabric or fiber layer 104 may be coated with a resorcinol formaldehyde resin or a solvated isocyanate.

Usually, this coating of the fiber layer 104 is completed as a separate step during manufacture of the fabric and it may not be part of the construction of the self-sealing container. Subsequently, in routine or submethod 520, the polyurethane reaction mixture layer 102 may be created. Further details of routine or submethod 520 are described below in connection with FIG. 6.

Next, in block 525, a first layer of the polyurethane reaction mixture 102D as illustrated in FIG. 4B of the intermediate product 300 is applied to the liner 202. The reaction mixture 102D is also applied to fabric layer 104B. When applying the reaction mixture 102D, the reaction mixture 102D is generally applied to be as thin (but not viscous) as possible. The method 500A then continues to block 535 of FIG. 5B.

FIG. 5B is a continuation flowchart of FIG. 5A illustrating the method 500B for forming a self-sealing volume 200 according to an exemplary embodiment. In block 535, a first coated fabric or fiber layer 104B is applied to the first layer 102D of the polyurethane reaction mixture 102D as illustrated in FIG. 4B. In an alternative exemplary embodiment, the polyurethane reaction mixture 102D may be applied to the coated fabric 104B and then these two layers 102D, 104B may be applied to the liner layer 202 in which the polyurethane reaction mixture 102D is sandwiched between the fabric layer 104B and the liner layer 202.

In block 540, a second layer of the polyurethane reaction mixture 102C is applied to the first coated fabric or fiber layer 104B of FIG. 4B. In block 545, sealant layer 106 may have a primer or adhesion activator coated on prior to application. Then, the sealant layer 106 is applied to the second layer of the polyurethane reaction mixture 102C as illustrated in FIG. 4B. As noted previously, the sealant layer 106 may comprise natural rubber or partially vulcanized natural rubber (NR) (having less than about 1% sulfur). Other materials that may be used include polyisoprene (IR), styrene butadiene (SBR), blends of SBR with NR or IR, and low durometer polyurethanes (approximately Shore A less than 70). In block 550, a third layer of the polyurethane reaction mixture 102B is applied to the sealant layer 106.

In block 555, a second coated fabric or fiber layer 104A is applied to the third layer of the polyurethane reaction mixture 102B as illustrated in FIG. 4B. In block 560, a fourth layer of the polyurethane reaction mixture 102A is applied to the second coated fabric or fiber layer 104A as illustrated in FIG. 4B. The method 500B then continues to block 575 of FIG. 5C.

FIG. 5C is a continuation flowchart of FIG. 5B illustrating the method 500C for forming a self-sealing volume according to an exemplary embodiment. In block 575, the coated preform 304 having the wall structure illustrated in FIG. 4B is rotated so that the polyurethane reaction mixture remains uniform throughout the fabric and over the preform 304 until the polyurethane reaction mixture layers 102 cool and become stiff. Next, in block 580, the coated preform 304 comprising the intermediate products 300A as illustrated in FIG. 4C is placed into a mold 400.

Subsequently, in block 585, the perform 304 forming the intermediate products 300A is closed within the mold 400 as illustrated in FIG. 4C. In block 590, heat and pressure may be applied to the mold 400 from heat source 410 and gas pressure source 403 in order to cure the preform 304 or intermediate product 300A to form the cured, single intermediate product 300C as illustrated in FIG. 4D. The gas pressure source 403 may fill the preform 304 and exit it while to expand the mold release layer 302 such that layer 302 pushes the composite wall structure/system 100 against the heated mold 400 during curing. Specifically, the gas pressure source 403 may inflate the elastomeric mold release layer 302 that is on the outside of the gas-permeable preform 304 so that the wall structure 100 (FIG. 1B) is pressed against the heated mold 400. Once the structure 300A of FIG. 4C cures into structure 300C of FIG. 4D, the fixture 507 may be removed from the nut ring 509.

In block 592, the inlet 503, metal fixture 507, preform 304 and corresponding elastomeric mold release layer 302 attached thereto may then be removed from the resultant cured volume 300C as illustrated in FIG. 4E to form the completed wall system or self-sealing volume 200 as illustrated in FIG. 4E. Specifically, the preform 304 and corresponding elastomeric mold release layer 302 may be broken into small pieces relative to the entire cured volume or wall system 200 and removed through nut ring 509 that penetrates through the volume formed by the wall system 200 as illustrated in FIG. 4E.

Next in block 593, if a volume liner 202 was not added in block 510, a volume liner 202 can be sprayed into the completed volume 300C so that a liquid impermeable coating completely covers the inside of the volume 300C. Liner 202 may comprise any elastomeric material that will have a greater resistance to hydrocarbon fuel 204 than a polyurethane elastomer. Exemplary materials for the liner material 202 include, but are not limited to, polyurethane, nitrile rubber, polysulfide, polyurea, polyvinylalcohol (PVA), Hydrogenated Nitrile Butadiene Rubber (HNBR), Epichlorohydrin rubber (ECO) and polyvinylidene fluoride.

Next, in block 594, the volume formed by the wall system 200 may be filled with a fluid For example, the fluid may comprise a hydrocarbon fuel, such as gasoline or diesel. The method 500 then ends after block 594.

FIG. 6 is a flowchart illustrating a routine or submethod 520 for creating a polyurethane reaction mixture layer 102 according to an exemplary embodiment. Block 605 is the first step of submethod or routine 520.

In block 605, an organic diisocyanate or diisocyanate prepolymer having a predetermined molecular weight is prepared. Normally, any of the well-known organic polyisocyanates useful for making castings may be utilized for the polyurethane reaction mixture layer 102. Toluene diisocyanate and methylene diphenyldiisocyanate are suitable exemplary materials as they are frequently used for making castings.

The amount of polyisocyanate used is about 0.9 to about 1.5 mole equivalents. The molecular weight that may be used for the organic diisocyanate may comprise a magnitude of approximately 250 g/mole. For a diisocyanate prepolymer, the magnitude may comprise approximately 624 g/mode or a free isocyanate percentage of between about 6.45 to about 6.74 percent.

Then, in block 610, the diisocyanate or diisocyanate prepolymer is mixed with a reactive hydrogen containing material having a predetermined molecular weight. Specifically, a reactive hydrogen-containing material having a molecular weight of about 700 to about 4000 may be used. Representative of the reactive hydrogen-containing materials are the broad classes of polyester polyols, polyether polyols, hydrocarbon-polyols. The polyester polyols that are preferred are the esters of adipic acid with the lower glycols such as ethylene glycol, propylene glycol, and butylene glycol, and mixtures of these. The polyether polyols that are preferred are propylene ether glycol, polypropylene ether polyol, and polytetramethylene ether polyol.

In conjunction with the polyol a short chain glycol, organic diamine, polyetheramine or alkylanolamine may be used to increase molecular weight of the polyurethane reaction mixture layer 102. Representative members of these classes of materials include, but are not limited to, ethylene glycols, propylene glycols, butane diols, methylene bis-chloroaniline, methylene dianiline, bis-amino phenyl sulfone and amino methyl propanol. If organic amines are used, then urea linkages will be created rather than urethane linkages, resulting in a mixed polyurethane urea.

Then, in block 615, the reaction product/layer 102 at this stage is not allowed to cure completely but it is allowed to cool after casting thereby stiffening. This is accomplished by keeping the polyurethane reaction mixture below the temperature at which curing will occur, typically below about 90° C. to about 150° C., and preferably below about 90° C. The polyurethane reaction mixture in block 615 may be applied to the preform at a temperature of between about 40.0° C. to about 75.0° C. As it cools, the reaction product will stiffen and become gel-like in a time period of between about 20.0 minutes to about 60.0 minutes, and preferably in about 20.0 minutes. The submethod then returns to block 525 of FIG. 5A.

Referring now to FIG. 7A1, this figure illustrates a cross-sectional view of a device 400C, 400D for forming flexible molds 400E, 400F according to an exemplary embodiment. The device 400C, 400D may comprise two flexible molds shells that are used to create flexible molds 400E, 400F. In the exemplary embodiment illustrated in FIG. 7A1, the two mold shells have the cross-sectional shape of one half of geometric hexagon. As noted previously, inventive method and system are not limited to the shapes described or illustrated in this disclosure. Other shapes are possible as understood by one of ordinary skill in the art.

The two rigidmolds shells 400C, 400D may comprise materials such as, but not limited to plaster, wood, molded plastic, clay, fiberglass composite, etc. One of the mold shells 400C, 400D may comprise an aperture or opening 405 such as mold shell 400D. This opening 405 will be used for a fixture 507 as will be described in further detail below.

As mentioned previously, FIGS. 7A and 7B illustrate one of several options for producing a preform. Other options/embodiments covered by this disclosure, but not illustrated, include three dimensional preform molds cut from a block of polyethylene or other similar material. In these other, alternative embodiments, the preform molds may be rigid (not flexible) as understood by one of ordinary skill in the art.

As illustrated in FIG. 7A1, the flexible molds 400E, 400F will generally have a shape that corresponds to the shape of the two rigid mold shells 400C, 400D. The flexible molds 400E, 400F previously made of a material such as, but not limited to, silicone, polyethylene, or polypropylene.

FIG. 7A2 is a cross-sectional view of the flexible molds 400E, 400F formed from the device 400C, 400D of FIG. 7A1 according to an exemplary embodiment. According to this exemplary embodiment, the two rigidmolds shells 400C, 400D have been removed so that only the flexible molds 400E, 400F each having one half of a hexagonal cross-sectional shape remain. As noted previously, one of the flexible molds 400F has an opening 405.

FIG. 7A3 is a cross-sectional view of preform material 304A, 304B positioned within the flexible molds 400E, 400F of FIG. 7A2 according to an exemplary embodiment. According to this exemplary embodiment, the preform material 304A, 304B will form a gas-permeable, solid structure. The preform material 304A, 304B may be generated by mixing equal parts of a diisocyanate such as sold under the tradename SMARTFOAM A and a polyol such as SMARTFOAM B. These mixtures are poured into the fabricated two piece molds 400E, 400F that usually have inside dimensions which correspond to the required outside dimensions of the preform 304. Once the preform material 304B of the mold 400F cures slightly (or prior to pouring of the preform material 304B) the mold 400F may be fitted with a metal fixture 507.

The metal fixture 507 of FIG. 7A3 will provide ingress for air and will serve as a mounting for the preform 304 during layup. The location of the metal fixture 507 is selected to coincide with the location of a nut ring 509 in the finished self-sealing volume 100.

FIG. 7A4 is a cross-sectional view of the two halves of a gas-permeable, solid preform 304A, 304B generated from the flexible molds 400E, 400F of FIG. 7A3 according to an exemplary embodiment. In this exemplary embodiment, the flexible molds 400E, 400F have been removed such that the gas-permeable, solid preform halves 304A, 304B remain. The second half 304B has the metal fixture 507 as described above. These halves 304A, 304B may be rotated as indicated by the directional arrows until completely cured. Rotation may or may not be used. In other embodiments, the halves 304A, 304B are not rotated. The material described above for the performs 304A, 304B generally cure at standard room temperature and pressure as understood by one of ordinary skill in the art.

FIG. 7A5 is a cross-sectional view of the two halves of the gas-permeable, solid preform 304A, 304B put/mated together according to an exemplary embodiment. The fully cured, two halves 304A, 304B are mated together by adhesives. Usually, adhesives that do not contain solvent or water may be employed. Such adhesives include, but are not limited to, epoxies or two part urethanes.

The resultant gas-permeable solid preform 304D may be characterized as a urethane preform 304D. This FIG. 7A5 also illustrates a coating 707 that may be applied to the preform surface to provide a smooth, rigid surface for build-up. Materials used for the coating 707 may include, but are not limited to, a rigid polyurethane such as FEATHERLITE® brand low-density urethane casting resin.

FIG. 7A6 is a cross-sectional view of the gas-permeable, solid preform 304D after apertures or holes 701 have been created within the preform 304D according to an exemplary embodiment. Any number of holes 701 may be created within the solid preform 304D. The holes 701 may be created with machines such as, but not limited to, drills or lasers. The holes 701 may be randomly positioned or positioned at evenly spaced intervals as understood by one of ordinary skill in the art. The holes 701 will help a fluid originating from the gaseous pressure source 403 to exit the preform 304D in order to properly inflate the release layer 302 as described above. Holes 701 are usually only needed if an impermeable skin (i.e. like FEATHERLITE® brand low-density urethane casting resin) is applied to the outside of the foam/solid preform 304D but can be used in any foam/solid preform 304D. Holes 701 are also usually needed in closed-cell foams forming the preform 304D which generally do not require the use of an outer shell (i.e like FEATHERLITE® brand low-density urethane casting resin). The depth of the holes 701 only need to penetrate the FEATHERLITE® brand low-density urethane casting resin, or close-cell foam skin but can penetrate further into the foam. The foam has pores which may connect to the holes 701. An open cell foam used for the solid preform 304D may not require any holes 701 in some instances.

The outer surface of the solid preform 304D may be sanded and finished to the desired internal dimension that may be used for the self sealing volume 100 once formed, as understood by one of ordinary skill in the art. “Finished,” as described herein, means to sand and smooth so as to remove cracks, seams and imperfections as understood by one of ordinary skill in the art.

Referring now to FIG. 7B1, this figure illustrates a cross-sectional view of a solid mold 400G, 400H for forming a gas-impermeable, hollow preform 304C according to an exemplary embodiment. This solid mold 400G, 400H is “solid” in the sense that its walls may comprise a solid material. However, the solid mold 400G, 400H may comprise a hollow interior 400Z so that a hollow type preform 304C (SEE FIG. 7B5) may be generated. The solid molds 400G and 400H are part of the submethod 502B described below in FIG. 9. Submethod 502B may comprise a form of roto casting (also known as rotacasting) as understood by one of ordinary skill in the art. Such rotacasting may use self-curing resins in unheated molds, and may share slow rotational speeds that are in common with rotational molding.

Similar to the exemplary embodiment illustrated in FIG. 7A, a portion, such as one half, of the solid mold 400G, 400H may comprise an opening 405 for receiving the fixture 505 (described above). The solid mold 400G, 400H may be made from materials such as metal, composites, etc. which can withstand curing temperatures for the hollow preform 304C (illustrated in FIGS. 7B5, 7B6).

FIG. 7B2 is a cross-sectional view of the solid mold 400G, 400H of B1 with a fixture 507 attached to a side 400G of the solid mold having an opening 405 according to an exemplary embodiment. The fixture 507 illustrated in FIG. 7B2 is similar to the one illustrated in FIG. 7A.

FIG. 7B3 is a cross-sectional view of the solid mold 400G, 400H in which a liquid state of preform material 304C is poured into the solid mold 400G, 400H via the fixture 507 according to an exemplary embodiment. The fixture 507 may receive a nozzle 503. The nozzle 503 may dispense the liquid state of the preform material 304C. The liquid state of the preform material 304C may comprise a material similar to the embodiment described in FIG. 7A. Specifically, the liquid state of the preform material 304C may comprise equal parts of a diisocyanate such as sold under the tradename FEATHERLITE Part A and a polyol such as FEATHERLITE Part B. The amount of diisocyanate used generally comprises enough to coat the mold and provide a uniform preform thickness of between about 1.0 mm to about 10.0 mm.

FIG. 7B4 is a cross-sectional view of the solid mold 400G, 400H containing the preform liquid material 304C while the solid mold 400G, 400H is being rotated according to an exemplary embodiment. Specifically, after a requisite amount of liquid preform material 304C is deposited in the solid mold 400G, 400H, the fixture 505 is sealed and the solid mold 400G, 400H is rotated such that the preform material 304C cures in attaches to the inner volume of the solid mold 400G, 400H in order to generate a gas-impermeable, hollow type preform 304C. The material described above for the perform 304C generally cures at standard room temperature and pressure as understood by one of ordinary skill in the art.

FIG. 7B5 is a cross-sectional view of the solid mold 400G, 400H being opened after curing of the preform liquid material 304C into a gas-impermeable, hollow preform 304C according to an exemplary embodiment. The hollow preform 304C retains the fixture 507 after curing. The hollow preform 304C may have thickness which ranges between about 1.0 mm and about 10.0 mm.

FIG. 7B6 is a cross-sectional view of the gas-impermeable, hollow preform 304C after apertures or holes 701 have been created within the preform according to an exemplary embodiment. Any number of holes 701 may be created within the hollow preform 304C. The holes 701 may be created with machines such as, but not limited to, drills or lasers. The holes 701 may be randomly positioned or positioned at evenly spaced intervals as understood by one of ordinary skill in the art. The holes 701 will help a fluid originating from the gaseous pressure source 403 to exit the preform 304D in order to properly inflate the release layer 302 as described above.

The outer surface of the hollow preform 304C may be sanded and finished to the desired internal dimension that may be used for the self sealing volume 100 once formed, as understood by one of ordinary skill in the art. “Finished,” as described herein, means to sand and smooth so as to remove cracks, seams and imperfections as understood by one of ordinary skill in the art.

FIG. 7C is a cross-sectional view of a device for forming flexible molds according to another exemplary embodiment.

Referring now to FIG. 7C, this figure illustrates a cross-sectional view of a device 400C, 400D for forming flexible molds 400E, 400F according to an exemplary embodiment. This figure is similar to FIG. 7A1 described above.

The device 400C, 400D may comprise two flexible molds shells that are used to create flexible molds 400E, 400F. The flexible mold shells 400C, 400D may comprise a combination of convex and concave geometries. For example, see convex regions 802A,B and concave regions 804A,B. Additional and/or fewer convex regions 802A,B and concave regions 804A,B may be provided without departing from the scope of this disclosure. Further, these convex regions 802A,B and concave regions 804A,B may be added to all molds described in this disclosure, such as those illustrated in FIG. 7B.

With the inventive wall system resulting from the molds described above, a complex three dimensional volume 200 may be generated which may or may not contain concave geometries 802, 804. Meanwhile, as understood by one of ordinary skill in the art, conventional and prior art mold systems may only produce convex geometries and not concave geometries as described above and illustrated in FIG. 7C. Conventional and prior art mold systems usually cannot produce concave geometries and/or a combination of convex and concave geometries in a final product, such as a self-sealing volume.

FIG. 8 is a flowchart 502A illustrating a routine or submethod 502A for generating the solid preform 304D of FIG. 7A according to an exemplary embodiment. Block 702 is the first step of routine 502A. This routine 502A corresponds with routine 502 described above in connection with FIG. 5A. As mentioned previously, routine 502 of FIG. 5A may have at least two different paths or methods, such as illustrated in FIG. 8 and FIG. 9.

In block 702 of FIG. 8, a flexible, reusable mold 400E, 400F as illustrated in FIGS. 7A1-A3 is created. The flexible, reusable mold 400E, 400F may be created with the use of supports or mold forms 400C, 400D as set forth in FIG. 7A1. The flexible, reusable mold 400E, 400F, once created, may be used to generate a preform 304.

In block 704, the flexible, reusable mold 400E, 400F is removed from supports 400C, 400D as illustrated in FIG. 7A2. In block 706, a fixture 507 may be positioned within an aperture 405 of a portion of the flexible, reusable mold 400E, 400F, such as in flexible mold 400F as illustrated in FIG. 7A3. The fixture 507 is positioned before the material for the preform 304B hardens.

In block 708, the material for the preform 304 is casted into the flexible, reusable mold 400E, 400F such as illustrated in FIG. 7A3. In block 710, the hardened preform materials forming preform sections 304A, 304B may be removed from the flexible and reusable mold 400E, 400F as illustrated in FIG. 7A4. Next, in block 712, the preform sections 304A, 304B may be fitted together and coupled permanently with the use of adhesives as illustrated in FIG. 7A5.

In optional block 714, the outside of or external layer of the preform 304D may be coated with a thermoset layer as illustrated in FIG. 7A5 with the nozzle 707 dispersing a coating. Next, in block 716, the preform 304D may be adjusted to precise dimensions that will correspond to the self-contained volume 100 described above. Specifically, in this block 716, adjusting may include sanding, buffing, cutting, shaving, and the like, to the preform 304D. Subsequently, in block 716, apertures/holes 701 may be created within the solid, gas-permeable preform 304D. The process then returns to block 505 of FIG. 5A.

FIG. 9 is a flowchart illustrating a routine or submethod for generating the hollow preform 304C of FIG. 7B according to an exemplary embodiment. Block 703 is the first step of routine 502B. This routine 502B corresponds with routine 502 described above in connection with FIG. 5A. As mentioned previously, routine 502 of FIG. 5A may have at least two different paths or methods, such as illustrated in FIG. 8 and FIG. 9.

In block 703 of FIG. 9, the reusable mold 400G, 400H such as illustrated in FIG. 7B1 may be assembled/prepared. This reusable mold 400G, 400H may produce hollow performs 304C as described above.

In block 705, a fixture 507 may be positioned within the reusable mold 400G, 400H. Specifically, one section 400G of the reusable mold 400G, 400H may have an aperture for receiving a fixture 507.

In block 707, preform material 304C may be poured in a liquid state from a nozzle 509 to the inside of the reusable mold 400G, 400H such as illustrated in FIG. 7B3. Next, in block 709, the reusable mold 400G, 400H may be sealed and then rotated in three dimensions while the liquid preform material 304C cures against the inside or internal wall of the reusable mold 400G, 400H.

In block 711, the hollow, gas-permeable preform 304C may be removed from the reusable mold 400G, 400H. The hollow gas-impermeable preform 304C may be adjusted to precise dimensions corresponding to the self-contained volume 100. Specifically, in this block 711, adjusting may include sanding, buffing, cutting, shaving, and the like, to the preform 304C. Subsequently, in block 713, apertures/holes 701 may be created within the hollow, gas-impermeable preform 304D. The process then returns to block 505 of FIG. 5A.

Polyurethane Reaction Mixture 102 Example 1

39 parts of a polyester polyol such as Baytec GSV 85A (which is a 2,000-molecular-weight polyethylene/polybutylene adipate diol) having a hydroxyl number of 55 were premixed with a 5 parts of butane diol at a temperature of about 50° C. To this polyol mixture, 100 parts of a polyester pre-polymer such as Baytec 242 (which is a modified diphenylmethane diisocyanate (MDI)-terminated polyester prepolymer), was added at a temperature of about 50° C. and mixed. The resulting polyurethane reaction mixture 102D was spread onto a foam polyurethane preform 304 that had been previously coated with a layer 302 of Smooth On EZ Spray SILICONE® 20 silicone (which is a 20 Shore A silicone elastomer) and a layer of inner liner 202 made from a polysulfide such as PRC Rapid Seal 655 aliphatic polysulfide sold by PRC-DeSoto International, Inc.

Next about a 24 oz NYLON fabric 104B that had been previously coated and dried with a solvated polyurethane, namely Estane 5714, an aliphatic polyurethane, or a polyether type thermoplastic polyurethane, was placed on the preform 304. This was followed by another layer of the same polyurethane reaction mixture 102C. Next, a layer of partially vulcanized natural rubber having less than about 1% sulfur, forming the sealant layer 106 was applied followed by adding another layer of the same polyurethane reaction mixture 102B. Subsequently, a layer of polyurethane coated 24 oz NYLON fabric 104A and a final layer of the same polyurethane reaction mixture 102A were applied.

The resulting “wet” composite of intermediate fuel tank 300 was rotated and turned until the polyurethane reaction mixture layers 102 cooled to yield a tacky but intractable coating. At this stage, the fuel tank was placed in one half of a three dimensional mold 400. The second half 400A of the mold was closed onto the first half 400B and the fuel tank 300A, 300B was cured for at least about 90.0 minutes at a temperature of about 120° C. and an air pressure of about 20 psi from the gaseous pressure source 403.

Polyurethane Reaction Mixture 102 Example 2

39 parts of a polyester polyol such as Baytec GSV 85A (which is a 2,000-molecular-weight polyethylene/polybutylene adipate diol) having a hydroxyl number of 55 were premixed with a 4 parts of propane diol at a temperature of about 50° C. To this polyol mixture, 100 parts of a polyester pre-polymer such as Baytec 242 (which is a modified diphenylmethane diisocyanate (MDI)-terminated polyester prepolymer) were added at a temperature of about 50° C. and mixed. The resulting polyurethane reaction mixture 102D was spread onto a foam polyurethane preform 304 that had been previously coated with a layer 302 of Smooth On EZ Spray SILICONE® 20 silicone (which is a 20 Shore A silicone elastomer) and a layer of inner liner 202 made from a polysulfide, such as PRC Rapid Seal 655 aliphatic polysulfide sold by PRC-DeSoto International, Inc.

Next, about a 24 oz NYLON fabric 104B that had been previously dried and coated with a solvated polyurethane, namely Estane 5714, an aliphatic polyurethane, or a polyether type thermoplastic polyurethane, was placed on the preform 304. This was followed by adding another layer of the same polyurethane reaction mixture 102C. Subsequently, a layer of partially vulcanized natural rubber having less than about 1% sulfur, forming sealant layer 106 was applied followed by another layer of the same polyurethane reaction mixture 102B. Subsequently, a layer of polyurethane coated 24 oz NYLON fabric 104A and a final layer of the same polyurethane reaction mixture 102A were applied.

The resulting “wet” composite of intermediate fuel tank 300 was rotated and turned until the polyurethane reaction mixture layers 102 cooled to yield a tacky but intractable coating. At this stage, the fuel tank was placed in one half of a three dimensional mold 400. The second half 400A of the mold was closed onto the first half 400B and the fuel tank 300A, 300B was cured for at least about 90.0 minutes at a temperature of about 120° C. and an air pressure of about 20 psi from the gaseous pressure source 403.

Polyurethane Reaction Mixture 102 Example 3

15 parts of a polyester polyol such as Baytec GSV 85A (which is a 2,000-molecular-weight polyethylene/polybutylene adipate diol) having a hydroxyl number of 55 were premixed with a 6 parts of butane diol at a temperature of about 50° C. To this polyol mixture, 100 parts of a polyester pre-polymer such as Baytec 242 (which is a modified diphenylmethane diisocyanate (MDI)-terminated polyester prepolymer) was added at a temperature of about 50° C. and mixed. The resulting polyurethane reaction mixture 102D was spread onto a foam polyurethane preform 304 that had been previously coated with a layer 302 of Smooth On EZ Spray SILICONE® 20 silicone (which is a 20 Shore A silicone elastomer) and a layer of inner liner 202 made from a polysulfide, such as PRC Rapid Seal 655 aliphatic polysulfide sold by PRC-DeSoto International, Inc. Next, about a 24 oz NYLON fabric 104B that had been previously dried and coated with a solvated polyurethane, namely Estane 5714, an aliphatic polyurethane, or a polyether type thermoplastic polyurethane, was placed on the preform 304.

This was followed by adding another layer of the same polyurethane reaction mixture 102C. Next, a layer of partially vulcanized natural rubber having less than about 1% sulfur, forming sealant layer 106 was applied followed by another layer of the same polyurethane reaction mixture 102B. Subsequently, a layer of polyurethane coated 24 oz NYLON fabric 104A and a final layer of the same polyurethane reaction mixture 102A were applied.

The resulting “wet” composite of intermediate fuel tank 300 was rotated and turned until the polyurethane reaction mixture layers 102 cooled to yield a tacky but intractable coating. At this stage, the fuel tank was placed in one half of a three dimensional mold 400. The second half 400A of the mold was closed onto the first half 400B and the fuel tank 300A, 300B was cured for at least about 90.0 minutes at a temperature of about 120° C. and an air pressure of about 20 psi from the gaseous pressure source 403.

Polyurethane Reaction Mixture 102 Example 4

39 parts of a polyester polyol such as Baytec GSV 85A (which is a 2,000-molecular-weight polyethylene/polybutylene adipate diol) having a hydroxyl number of 55 were premixed with a 4 parts of butane diol and 1.4 parts of an Alkoxylated trimethylolpropane such as Curene 93 (which is an ethoxylated trimethylol propane with a hydroxyl number of 610) at a temperature of about 50° C. To this polyol mixture, 100 parts of a polyester pre-polymer such as Baytec 242 (which is a modified diphenylmethane diisocyanate (MDI)-terminated polyester prepolymer) were added at a temperature of about 50° C. and mixed.

The resulting polyurethane reaction mixture 102D was spread onto a foam polyurethane preform 304 that had been previously coated with a layer 302 of Smooth On EZ Spray SILICONE® 20 silicone (which is a 20 Shore A silicone elastomer) and a layer of inner liner 202 made from a polysulfide such as PRC Rapid Seal 655 aliphatic polysulfide sold by PRC-DeSoto International, Inc. Next, about a 24 oz NYLON fabric 104B that had been previously dried and coated with a solvated polyurethane, namely Estane 5714, an aliphatic polyurethane, or a polyether type thermoplastic polyurethane, was placed on the preform 304.

This was followed by adding another layer of the same polyurethane reaction mixture 102C. Next, a layer of partially vulcanized natural rubber having about forming sealant layer 106 was applied followed by another layer of the same polyurethane reaction mixture 102B. Subsequently, a layer of polyurethane coated 24 oz NYLON fabric 104A and a final layer of the same polyurethane reaction mixture 102A were applied.

The resulting “wet” composite of intermediate fuel tank 300 was rotated and turned until the polyurethane reaction mixture layers 102 cooled to yield a tacky but intractable coating. At this stage, the fuel tank was placed in one half of a three dimensional clam shell mold 400. The second half 400A of the mold was closed onto the first half 400B and the fuel tank 300A, 300B was cured for at least about 90.0 minutes at a temperature of about 120° C. and an air pressure of about 20 psi from the gaseous pressure source 403.

Polyurethane Reaction Mixture 102 Example 5

39 parts of a polyester polyol such as Baytec GSV 85A (which is a 2,000-molecular-weight polyethylene/polybutylene adipate diol) having a hydroxyl number of 55 were premixed with a 4 parts of butane diol, 1.4 parts of an ethoxylated trimethylol propane with a hydroxyl number of 610 (available under the tradename Curene 93 by Anderson Development Company of Adrian, Mich.) and 1.3 parts of trimethylolpropane monoallyl ether with a hydroxyl number of 640 at a temperature of about 50° C. To this polyol mixture, 100 parts of a polyester pre-polymer such as Baytec 242 (which is a modified diphenylmethane diisocyanate (MDI)-terminated polyester prepolymer) was added at a temperature of about 50° C. and mixed.

The resulting polyurethane reaction mixture 102D was spread onto a foam polyurethane preform 304 that had been previously coated with a layer 302 of Smooth On EZ Spray SILICONE® 20 silicone (which is a 20 Shore A silicone elastomer) and a layer of inner liner 202 made from a polysulfide, such as PRC Rapid Seal 655 aliphatic polysulfide sold by PRC-DeSoto International, Inc. Next, about a 24 oz NYLON fabric 104B that had been previously dried and coated with a solvated polyurethane, namely Estane 5714, an aliphatic polyurethane, or a polyether type thermoplastic polyurethane, was placed on the preform 304.

This was followed by adding another layer of the same polyurethane reaction mixture 102C. Next, a layer of partially vulcanized natural rubber having about less than 1% sulfur, forming sealant layer 106 was applied followed by another layer of the same polyurethane reaction mixture 102B. Subsequently, a layer of polyurethane coated 24 oz NYLON fabric 104A and a final layer of the same polyurethane reaction mixture 102A were applied.

The resulting “wet” composite of intermediate fuel tank 300 was rotated and turned until the polyurethane reaction mixture layers 102 cooled to yield a tacky but intractable coating. At this stage, the fuel tank was placed in one half of a three dimensional mold 400. The second half 400A of the mold was closed onto the first half 400B and the fuel tank 300A, 300B was cured for at least about 90.0 minutes at a temperature of about 120° C. and an air pressure of about 20 psi from the gaseous pressure source 403.

The measurements below Table 1 listed below show the difference between the system 200/method 500 and a conventional method for forming self-sealing volumes. While the self-sealing volumes formed by the inventive system/method and the conventional method had different shapes relative to each other, their dimensions demonstrate some significant advantages with the inventive system 200 and method 500. The outer dimensions of each volume have been compared. What this data shows is that there is more dimensional variability in the conventional method for forming a self-sealing volume compared to the inventive system 200 and method 500.

The coefficient of variation (CV), a measure of the extent of variability in relation to mean of the population, is between about 0.35% and about 0.49% for the conventional method. Meanwhile, it's between about 0.072% and about 0.080% for the inventive method 500 and system 200. Comparing this data, this is an improvement of between at least five to about six times (500-600%) with the invention. It is believed that the inflation of the polyurethane mixture layers 102 via inflation of the mold release layer 302 against the mold 400 is at least one element which contributes to this improvement dimensional stability over the conventional art.

TABLE 1 CONVENTIONAL SELF SEALING VOLUME VS. INVENTIVE SELF-SEALING VOLUME SELF-SEALING VOLUME OF CONVENTIONAL SELF-SEALING INVENTIVE SYSTEM 200 AND VOLUME METHOD 500 Measure- Measure- Measure- Measure- ment 1 ment 2 ment 1 ment 2 Measure- Date VOLUME Width 2″ Width 5″ Date VOLUME Width 2″ Width 5″ ment Measured ID from end from end Measured ID from end from end 1 Sep. 10, 2012 1. 17.59 17.48 Sep. 19, 2012 23. 19.76 19.78 2 Sep. 10, 2012 2. 17.59 17.53 Sep. 19, 2012 24. 19.8 19.82 3 Sep. 10, 2012 3. 17.57 17.6 Sep. 19, 2012 25. 19.8 19.81 4 Sep. 10, 2012 4. 17.52 17.58 Sep. 19, 2012 26. 19.79 19.78 5 Sep. 10, 2012 5. 17.58 17.5 Sep. 19, 2012 27. 19.77 19.79 6 Sep. 10, 2012 6. 17.61 17.6 Sep. 19, 2012 28. 19.8 19.8 7 Sep. 19, 2012 7. 17.67 17.54 Sep. 19, 2012 29. 19.78 19.79 8 Sep. 19, 2012 8. 17.65 17.38 Sep. 19, 2012 30. 19.78 19.75 9 Sep. 19, 2012 9. 17.59 17.4 Sep. 19, 2012 31. 19.79 19.8 10 Sep. 19, 2012 10. 17.57 17.41 Sep. 19, 2012 32. 19.8 19.81 11 Sep. 19, 2012 11. 17.58 17.6 Sep. 19, 2012 33. 19.8 19.79 12 Sep. 19, 2012 12. 17.62 17.49 Sep. 19, 2012 34. 19.78 19.8 13 Sep. 20, 2012 13. 17.59 17.46 Sep. 19, 2012 35. 19.81 19.8 14 Sep. 20, 2012 14. 17.7 17.5 Sep. 19, 2012 36. 19.8 19.79 15 Sep. 20, 2012 15. 17.61 17.49 Sep. 19, 2012 37. 19.8 19.8 16 Sep. 20, 2012 16. 17.67 17.61 Sep. 19, 2012 38. 19.81 19.8 17 Sep. 20, 2012 17. 17.51 17.59 18 Sep. 20, 2012 18. 17.45 17.39 19 Sep. 20, 2012 19. 17.66 17.48 20 Sep. 20, 2012 20. 17.55 17.37 21 Sep. 20, 2012 21. 17.66 17.39 22 Sep. 20, 2012 22. 17.68 17.35 Average 17.60 17.49 19.79 19.79 Std Dev 0.061 0.086 0.014 0.016 % CV 0.35% 0.49% 0.072% 0.080%

Certain steps in the processes or process flows described in this specification naturally precede others for the invention to function as described. However, the invention is not limited to the order of the steps described if such order or sequence does not alter the functionality of the invention. That is, it is recognized that some steps may preformed before, after, or parallel (substantially simultaneously with) other steps without departing from the scope and spirit of the invention.

For example, in an alternative exemplary embodiment, the urethane reaction mixture 102 may be applied according to the following sequence: to the inner liner 202, similar to step 525; then, the reaction mixture 102 may be applied to the fabric layer 104; then the fabric layer 104 may then be applied to the inner liner 202, similar to step 525; then the reaction mixture 102 may be applied to the fabric layer 104 again; then, the sealant layer 106 may be applied, similar to step 545; and then, the reaction mixture 102 may be applied to a second fabric layer 104.

In some instances, certain steps may be omitted or not preformed without departing from the invention. Further, words such as “thereafter”, “then”, “next”, etc. are not intended to limit the order of the steps. These words are simply used to guide the reader through the description of the exemplary method.

As noted previously, at least one inventive aspect of the inventive system and method is that the preform 304 is inflated during cure of the polyurethane reaction layer 100. With this inflation of the preform 304, the polyurethane reaction layer 100 conforms to the exact dimensions of the mold 400 which holds the preform 304 and the polyurethane reaction mixture 100 sandwiched there between. This process yields a dimensionally correct/precisely built self-sealing volume 200.

According to an additional exemplary embodiment, a first barrier layer (not illustrated) may be provided between the liner 202 and the sealant 106. The purpose of the barrier layer is to limit the permeation of fuel 204 over time through the inner liner layer 202, the polyurethane reaction mixture layer 102D, the fabric layer 104B, and the polyurethane reaction mixture layer 102C. A second barrier layer, like the first barrier layer (both not illustrated) may also be provided on the exterior of the self-sealing volume 200 to also limit fuel permeation from fuel 204 that may come in contact with the volume 200, such as through a spill or leak from another volume or source.

Although selected aspects have been illustrated and described in detail, it will be understood that various substitutions and alterations may be made therein without departing from the spirit and scope of the present invention, as defined by the following claims. 

What is claimed is:
 1. A method for making a self-sealing volume, the method comprising: generating a preform; coating the preform with a gas-impermeable elastomeric release first material that forms a gas impermeable seal around a geometry of the preform; coating the preform with a second material for forming the self-sealing volume; placing the preform having the second material into a mold; inflating the second material against the mold; and curing the second material with the mold to form the self-sealing volume.
 2. The method of claim 1, wherein the preform is constructed of a third material comprising at least one of polyurea, polyurethane, polyester, plaster and polystyrene.
 3. The method of claim 1, wherein the gas-impermeable elastomeric mold release first material which forms the gas impermeable seal comprises at least one of: a silicone, an elastomeric silicone, a polyvinyl alcohol (PVA) and a polyolefin mold release agent.
 4. The method of claim 1, wherein the second material for forming the self-sealing volume comprises a composite of elastomeric material and fabric.
 5. The method of claim 4, wherein the composite of elastomeric material and fabric includes a self-healing layer for sealing after ballistic penetration.
 6. The method of claim 1, further comprising creating one or more apertures within the preform.
 7. The method of claim 1, further comprising adjusting a size of the preform.
 8. The method of claim 1, further comprising providing a nut ring that is coupled to the volume.
 9. The method of claim 1, further comprising creating the second material with a polyurethane reaction mixture that has a cast polyurethane derived from a neat polyurethane monomer reaction mixture that does not substantially react at room temperature, the polyurethane monomer reaction mixture comprising a reaction product of an organic polyisocyanate and a reactive hydrogen-containing material reacted with a mixture of a monomeric polyol and polymeric polyols.
 10. The method of claim 9, further comprising applying a liner third material to the gas-impermeable elastomeric release first material after the preform is fully cured.
 11. The method of claim 10, further comprising applying the polyurethane reaction mixture onto the liner third material.
 12. The method of claim 11, further comprising applying a layer of a fabric that has been precoated onto the polyurethane reaction mixture.
 13. The method of claim 12, further comprising applying a sealing layer onto the polyurethane reaction mixture.
 14. The method of claim 1, further comprising inflating the second material against the mold at a pressure between about 2.0 psi to about 80.0 psi.
 15. The method of claim 14, further comprising curing the second material with the mold at a temperature between about 80.0° C. to about 175.0° C.
 16. The method of claim 15, further comprising curing the second material with the mold for a duration between about 20.0 minutes to about 360.0 minutes. 